A special type of die forming using a high pressure Hydraulic fluid to press room temperature working material into a die

Discovered by HOLMSTROEM, MARTIN

There are three types of hydroforming:

1. Tube hydroforming

2. Sheet hydroforming

3. Explosive hydroforming

Used when a complex shape is needed

A section of cold-rolled steel tubing is placed in a closed die set

A pressurized fluid is introduced into the ends of the

tube

The tube is reshaped to the confine of the cavity

Involves forming of sheets with application of fluid pressure

Metal blank is subjected to hydraulic counter pressure generated by punchs

Required deformation takes placeNote: Sheet hydroforming provides a work-hardening effect as the

steel is forced against the blanks through fluid pressure.

Used for large parts Generates the forming pressure by a

simple explosion above the part which is immersed in water.

1. Outer skin with its extreme demand of surface quality and dimensional accuracy.

2. Longer outer skin parts for passenger cars, utility vehicles

3. Low capital cost. Fewer and simpler dies.

4. Better NHV (noise, vibration and harshness )factors.

5. Reduction in weight.

7. High process capability.

8. Reduction in cost of component.

Steel (mild and harder steels) Stainless Steel Aluminum alloys Research continues to expand the

capabilities of the hydroforming process

Extraordinary Design Flexibility.

Fewer Parts

Less Assembly

Less Weight.

Lower Tooling Costs.

Less Post-Processing

Greater Integrity (pressure flows the metal into

corners for greater precision rather than

streching)

Results compared to conventional steel body structure:

50% less weight 45% less parts (less tools, less assembly) 45% less welding seams Tighter tolerances

Volvo Hydroformed Structure concept in Aluminum, (Schuler Hydroforming 1998)

Slow cycle time

Expensive equipment and lack of extensive knowledge base for process and tool design

Requires new welding techniques for assembly.

Hydroforming is an innovative forming process

Hydroforming is becoming more popular (ie.automotive and aerospace industries)

The advantages outweigh the limitations

Material selection is broad and continues to increase

Information can be found everywhere!